Digital Revolution is transforming every phase of the manufacturing value chain, unlocking the real potential of
Manufacturing by connecting the entire supply chain systems with latest and greatest technologies like
Cloud, Mobile, IoT, Machine Learning & Artificial Intelligence (AI) on
Enterprise Software Platforms. These Digital Technologies are changing the manufacturing landscape forever.
Digital Manufacturing is synonymous to Digital Factory, Smart Factory & Digital Twin. Digital Manufacturing technologies will recreate the real Manufacturing (Factory & Process) into a Digital Factory (A Digital Twin of Real Factory), enabling us to visualize, analyze, simulate real life manufacturing processes & scenarios in a Digital Factory to identify and resolve potential risks and process flaws to build an optimized and efficient Manufacturing environment.
Industry 4.0 with embedded IOT sensors and firmware software are making machines more intelligent to improve automation. These embedded IoT sensors record each machine action and generates huge data making it Big Data. This Big data is processed through Machine learning algorithms helping machines to learn and adapt through experience making machines smarter. Artificial Intelligence (AI) is a science of applying machine learning, deep learning techniques on Big Data and building smarter machines / applications which can understand human requests, connect data points draw conclusions and recommend optimal solutions.
Automation in Manufacturing evolved over the last century in 1st, 2nd and 3rd Industrial revolutions enabling mechanization, mass production and computerization in streamlining the production processes. We are in the midst of 4th Industrial revolution aka Industrial Internet of Things (IIoT) or Industry 4.0, where the current automation methodologies are enhanced with smart, autonomous and embedded systems to transform every touch point in the entire supply value chain.
Product Lifecycle Management (PLM) is a comprehensive system / solution that integrates the lifecycle of Product from inception to the disposal. Our PLM solution has multiple modules to manage Project, Requirements, Designs, Documents, BOMs, Variants, Configuration, Change Management, Release & Process workflows, manufacturing process planning, Operation Planning, Time Management, Robotics, Simulation, Work Instructions, Technical documents to name a few.
Every product goes through a number of iterations of designs before it gets through to manufacturing. Managing these iterations and keeping track of the history of changes is key to good data management. Many key decisions are made during the design phase. Mechanical design forms the basis for high level bill-of-material and initial cost estimation is done based on the BOM.
Similar to mechanical designs, electronic designs have go through similar iterations. They have their own bill of materials. Component data from electronic designs must contain some basic information like part numbers, reference designators, etc. Design Engineers will be able to access the component data from their CAD tools and be able to push data into PLM.
These days software components are have become an integral part of any technology product. Managing these components, their history, versions, etc. is no different than managing mechanical and electronic designs. Version control management for source code in software components is provided in our solution. The release process in version control system and PLM is synchronized so that they can be traced back to each other.
Program management solution helps streamline the planning and execution. Program management solution which are part of PLM portfolio, there will be seamless integration among Requirements, Product and Program execution. Program/Project planning is a sequence of activities/tasks which are associated with Requirements, Time, Resources and Cost. Once Planning is finalized then the project is tracked through the project execution phase.
Better Ideas are the source of Innovation and innovation leads to competitive advantage. An organization's innovation is very much dependent on how well they are capturing, managing and prioritizing the ideas from all stakeholders and effectively incorporating them into the products much faster than competition and leading the market innovation. Product ideas and concepts are developed and validated with the market first. This process of gathering, developing and validating must be formalized and streamlined to get the best results.
Requirements defines features and functions of the product. Prioritized and Approved Ideas are converted to requirements and managed throughout its lifecycle. Requirements comes from many sources and in many formats, these requirements are first captured and authored and then reviewed, verified and validated. The approved requirements will be part of future Product release. Throughout the lifecycle there may be many changes to these requirements, handled effectively using change management policies and supporting workflows.
Items and Documents are the basic objects in our PLM system. Though they are very similar to each other in terms of how they are managed, there are few differences. Revision management is key to both items and documents as they go through changes over time. All the associated data like BOMs, references, changes, vendor parts, etc. is managed in our system.
Accurate bill-of-materials is key to any manufacturing process. Cassini's Digital Manufacturing Solution provides comprehensive BOM Management. These BOMs include mechanical parts, electronic components, software components, and other types of items. BOM redlining allows to track changes between item revisions. BOM configuration management allows to define a set of parameters like effectivity dates to define item BOMs. Variant BOM Management allows to select options and option values to create the final BOM.
Product Configuration Management is a complex process where various options are provided to customers to configure their products. Cassini's solution provides a constraint-based configuration tool which allows the product managers to define the rules for the constraints. These constraints not only affect the product structures but also the manufacturing processes based on the selections. Unique Part Numbers or SKUs can be assigned to each product configuration for predefined configurations.
Having access to CAD models and drawings downstream in the value chain and not just in the design phase of product development improves collaboration between teams and enhances the quality of the product. Cassini's Visualization Module provides the ability to view and markup 2D and 3D CAD drawings and models. Manufacturing teams can view the same CAD models as the engineering teams without the need for expensive CAD tool licenses. Teams can collaborate with each other by providing feedback on the drawings using extensive markup capability.
Large amounts of data is generated and managed throughout the product development cycle, from idea to design, manufacturing and finally end-of-life. Finding information becomes difficult and forces users to duplicate data or create redundant data. This is inefficient and prone to errors which can be costly. Cassini's Enterprise Search module provides a number of features to make it easy and safe to search all product data. This includes ideas, requirements, designs, files, items documents, changes, manufacturing flows, operations, quality parameters, etc. Data is indexed at the time of creation and updated when changes are made. This keeps the index and the data in sync.
Production Planning & Scheduling is all about efficient planning, efficient utilization of resources, effective execution and most importantly react to any changes efficiently and fast. So overall in Production Planning & Scheduling efficiency is our primary focus. When efficiency is our top priority, then static planning tools are of no use, we need to focus on dynamic planning & smart scheduling solutions which are driven my machine learning algorithms on a real-time data. Smart manufacturers need to take smart decisions based on input from Smart machines and Smart AI Applications.
MES & MOM (Manufacturing Operations Management) are two acronyms which are related to improving manufacturing operations efficiency. Having an MES / MOM Systems is vital for Smart Digital Transformation. MES / MOM bridges shop floor machines (PLCs) to top floor management, providing timely and valuable information to the decision makers. The data from MES / MOM will be analysed in real-time using machine learning algorithms make the operations run smoothly.
Planning and managing resources and materials is key to running lean manufacturing operations. Cassini's digital manufacturing solution provides a smart MRP system driven by machine learning and artificial intelligence. It predicts the material requirements based on past data like, lead time, seasonality, etc. and provides a number of tools to make smart decisions.
Physical assets such as manufacturing plants and equipment are critical to operational success: their run times and down times play a key role in operational productivity and profitability. Cassini's Enterprise Asset Management (EAM) manages the life cycle of physical assets within an organization. Combined with CMMS (computerized maintenance management software), EAM facilitates solutions and transparency across Maintenance and Operations. The objective of EAM is to minimize life cycle asset costs while maximizing profitability and business continuity.
When manufacturing assets fail, the downtime results in lower capacity utilization and delays in production which ultimately affects the bottom line of any company. Over the recent years many organizations are adopting Predictive Maintenance to avoid such problems. Predictive Maintenance is a proactive maintenance strategy that tries to predict when a piece of equipment or machine might fail so that maintenance work can be performed before it happens. Cassini's Predictive Maintenance module provides a number of features to collect the data from sensors, analyze it and provide alerts automatically.
Quality Management at various levels is key to building good products. Cassini's Product Quality Management (PQM) module provides a number of features to define, monitor and act for quality control operations. PQM includes the following four major components. They are quality planning, quality control, quality assurance, and quality improvement. Integration of quality management with item management and change management provides traceability, which improves overall product quality.
Paper-based work instructions are inefficient, error prone and hard to manage. With Cassini's Electronic Work Instructions module, you can improve overall product quality, improve collaboration between your design, production, quality and service teams and provide easy access with mobile devices like tablets and phones, richer content with embedded multimedia (3D, video, audio and images). With seamless integration with product lifecycle management, work instructions can be synchronized for various operations like assembly operations, repair stations, equipment maintenance and process control.
Technical Documentation – create & manage – in engineering and manufacturing is very critical throughout product’s lifecycle. This technical document covers almost every detail like Technical Drawings, Assembly drawings, CAM Data, BOM, production processes and plans, quality inspection, control plans, SOPs, service, installation, commissioning and many more. Creating TechDocs in word processing tools is very tedious and then managing multiple version is next to impossible. With our Digital Manufacturing solution, throughout the processes at each stage we are capturing all the above data elements in Our PDM, PLM, MES solutions. So, we can quickly generate Technical Documents based on custom template much faster, more accurate and in multiple formats.
Suppliers are an integral part of your product value chain. Collaboration with your suppliers throughout this value chain is important to your product development. Parts and materials will be sourced from various suppliers at different stages of your product development. Managing your supply chain data and integrating it with your product data provides visibility into key information parameters like lead time, quality, cost, etc. Cassini's vendor collaboration module seamlessly integrates your supply chain processes with your product development and manufacturing.
Due to stringent regulatory requirements of various countries, product compliance management has to be part of the product operations for any organization. Tracking amounts of regulated substance like lead, mercury, etc. with the ability to audit your product records for non-conformance are the main features of Compliance Management. This module tracks compliance of your product using its BOM and manufacturer parts across multiple suppliers.
Inventory control may be the single most important factor in improving shop floor efficiency, part and materials accuracy and ultimately, your bottom line. From tracking inventory and outsourced parts throughout the manufacturing process, to reducing physical inventory time and forecasting necessary materials to meet demands, Cassini's Inventory Management module provides a number of features.
Field service is often the most direct interaction with the customer during the service life cycle, making it a priority for manufacturers that want to improve engagement. Moreover, with the move toward more preventative and prescriptive maintenance models, service organizations need to orchestrate technicians, parts, and vehicles in a complex network that delivers just-in-time service that is both cost effective and value additive.